Maintenance

ENGINE SPEED
S

ENGINE SPEED

ENGINE SPEED

ENGINE SPEED


5 Select FWD or REV in the selected range gear
6 Once the oil temperature reaches 70° C [158° F] check max. stall speed at full throttle in all gears.
7 The figure obtained should be within 50 RPM as mentioned in the vehicle handbook and should be
equal in all gears. Between gears allow the converter outlet temperature to cool down
to 70° C [158° F] by selecting neutral.
8 Leave the stall mode with the M button or switch-off the ignition
If max. stall speed measured is below specifications, it could indicate an engine or converter problem.
If max. stall speed measured is above specifications, it could indicate slipping clutches.

CAUTION
Do not operate the converter at stall condition longer than 30 seconds at one time, shift to
neutral for 15 seconds and repeat the procedure until desired temperature is reached.

Excessive temperature 120° C [250° F] maximum will cause damage to transmission clutches,
fluid, converter and seals.

TE27/32 4 SD 03/2010 7-61

Transmission Operation

7.2.2 Transmission pressure checks

Transmission problems can be isolated by the use of pressure tests. When the stall test indicates slipping
clutches, then measure clutch pack pressure to determine if the slippage is due to low pressure or clutch
plate friction material failure.
In addition, converter charging pressure and transmission lubrication pressure can also be measured.

7.2.3 Mechanical and electrical checks

Prior to checking any part of the system for hydraulic function (pressure testing), the following mechanical
and electrical checks should be made:
• Check the parking brake and inching pedal for correct adjustment.
• Be sure all lever linkage is properly connected and adjusted in each segment and at all connect-
ing points.
• The controls are actuated electrically. Check the wiring and electrical components.
• Be sure that all components of the cooling system are in good condition and operating correctly.
The radiator must be clean to maintain proper cooling and operating temperatures for the engine and
transmission. Air clean the radiator, if necessary.

7.2.4 Hydraulic checks

Also, before checking the transmission clutches, torque converter, charging pump and hydraulic circuit for
pressure and rate of flow, it is imporatant to make the following transmission fluid check:

• Check oil level in the transmission. The transmission fluid must be at the correct (full level).

• All clutches and the converter and its fluid circuit lines must be fully charged (filled) at all times.

Note:

the transmission fluid must be at operating temperature of 82 - 93° C [180 - 200° F] to

obtain correct fluid level and pressure readings.

Do not attempt to make these checks with cold oil.

To raise the oil temperature to this specification it is necessary to either operate (work) the vehicle or run
the engine with converter at “stall” (refer to 6.2.1 “stall test”).

Caution:

Be carefull that the vehicle does not move unexpectedly when operating the engine and
converter at stall RPM.

7.2.5 Controller (APC200): Please refer to functional description

TE27/32 4 SD 03/2010 7-62

Transmission Operation

7.3 TROUBLESHOOTING GUIDE

Refer to the following troubleshooting guide for the diagnosis of typical transmission troubles

7.3.1 Low clutch pressure

Cause Remedy

1. Low oil level. 1. Fill to proper level.

2. Clutch pressure regulating valve stuck open. 2. Clean valve spool and housing.
3. Faulty charging pump. 3. Replace pump.
4. Broken or worn clutch shaft or piston sealing rings. 4. Replace sealing rings.

7.3.2 Low charging pump output flow

Cause Remedy

1. Low oil level. 1. Fill to proper oil level.

2. Suction screen clogged. 2. Clean suction screen.
3. Defective charging pump. 3. Replace charging pump.

7.3.3 Overheating

Cause Remedy

1. Worn oil sealing rings 1. Remove, disassemble and rebuild converter

assy.
2. Worn charging pump. 2. Replace charging pump.
3. Low oil level. 3. Fill to proper level.
4. Dirty oil cooler. 4. Clean cooler.
5. Restriction in cooler lines. 5. Change cooler lines.

7.3.4 Noisy converter

Cause Remedy

1. Worn charging pump. 1. Replace charging pump.

2. Worn or damaged bearings. 2. A complete disassembly will be necassary to
determine which bearing is faulty.

7.3.5 Lack of power

Cause Remedy

1. Low engine RPM at converter stall. 1. Tune engine, check governor.

2. See “Overheating” and make same checks. 2. Make corrections as explained in “Overheating”.

TE27/32 4 SD 03/2010 7-63

Transmission Operation
7.4 CHECK POINTS

Port 42
Pressure check port
2nd clutch

Port 46
Pressure check port
Rev. clutch

Port 34 Port 44
Pressure check port Pressure check port
Lube 4th. clutch

FRONT VIEW Plug - Magnetic drain

M22 x 1.5 UNI

Port 16b
From remote filter 1

Port 32
Pressure check port
To cooler

Temperature switch

Temperature sensor

Port 43
Pressure check port
3rd clutch

REAR VIEW

TE27/32 4 SD 03/2010 7-64

Transmission Operation

7.4 CHECK POINTS (continued)

Port 11
Port 31
To cooler
Pressure check port
Regulator
Port 37
Pressure check port
Convertor in Engine speed
sensor

Port 45
Pressure check port
Fwd clutch
Drum speed sensor

Port 12
Output speed sensor From cooler
Port 16A
From remote filter
Turbine speed sensor
Metric flange for dip-
stick dia 25.4mm 4 Mounting holes
M20 x 2.5 THD
RIGHT VIEW 30mm DEEP

right

Port 41
Pressure check port
1st clutch

Oil level check port

¼ NPT
LEFT VIEW

TE27/32 4 SD 03/2010 7-65

left
Transmission Operation
7.4 CHECK POINTS (continued)

Port 13b Port 13a

To remote filter To remote filter
from pump 2 from pump 1

Oil fill hole

¾-14NPTF

TOP VIEW

top

TE27/32 4 SD 03/2010 7-66

Transmission Operation
7.4 CHECK POINTS (continued)

Checkpoint 31A.............. System pressure

Checkpoint 41................ 1st clutch pressure
Checkpoint 42................ 2nd clutch pressure
Checkpoint 43................ 3rd clutch pressure
Checkpoint 44................ 4th clutch pressure
Checkpoint 45................ FWD clutch pressure
Checkpoint 46................ REV clutch pressure
Checkpoint 66................ FWD/REV regulated pressure
Checkpoint 67................ 1st/3rd regulated pressure
Checkpoint 68................ 2nd/4th requlated pressure

31A

45

66

46

68

67 43

44
41

42

TE27/32 4 SD 03/2010 7-67

Transmission Operation
7.5 SPEED SENSOR - STATIC STANDALONE TEST

In order to be able to sense the currents, a series resistor of e.g. 200 Ω must be used. This resistor is integrated
in the controller, but when the sensor is to be used, it must be connected externally.

The idea is to connect the sensor to an external power source and measure the DC voltage across the series
resistor.

The voltage reading should be either 1.2V (from the 7mA ± 1mA current level) or 2.6 - 3.0V (for the 14mA ± 1mA
current level).

If the teeth can be moved slowly, distinct toggling between the two levels should be noticed.

TE27/32 4 SD 03/2010 7-68

Transmission Operation
7.6 Full flow valve components

FWD/REV
SELECTOR
VALVE A

FWD/REV
PROPORTIONAL
VALVE
2ND/4TH
PROPORTIONAL
VALVE
3RD/1ST
PROPORTIONAL
VALVE

1ST/3RD
4TH/2ND SELECTOR
SELECTOR VALVE
VALVE

4TH/2ND
PRESSURE
SENSOR

3RD/1ST
PRESSURE
SENSOR

TE27/32 4 SD 03/2010 7-69

8 SECTIONAL VIEWS & PARTS IDENTIFICATION

TE27/32 4SD 03/2010 8-70

TORQUE CONVERTER GROUP

TE32
CONVERTER HOUSING GROUP
13

7 33
8 32
38 37 30
29

42 34
43 35
40 31
19
41 21
14 18
1 17
15 19
20
42 18
43
40 19
41 3 20
18
16
35 13
36 23
22 44
37 45
38
10 21
6
9
12 3
11
39
39
7
5
4
10 3
41

8 27 40
12 9
11 25
43

42
27
26

28
24

GRP-32011 rev.092002
TE27/32 4 SD 03/2010 8-71
TORQUE CONVERTER GROUP

Item Description Qty

1 Torque Converter...................................................................................................................... 1
2 Not Illustrated............................................................................................................................ 1
3 Plug - Expansion...................................................................................................................... 3
4 Plug ......................................................................................................................................... 1
5 “O” Ring.................................................................................................................................... 1
6 Tube.......................................................................................................................................... 1
7 Tube.......................................................................................................................................... 1
8 Tube.......................................................................................................................................... 1
9 Clip............................................................................................................................................ 2
10 “O” Ring.................................................................................................................................... 2
11 Capscrew.................................................................................................................................. 2
12 Lockwasher............................................................................................................................... 2
13 Tube.......................................................................................................................................... 1
14 Sleeve....................................................................................................................................... 1
15 Sleeve....................................................................................................................................... 1
16 Sleeve....................................................................................................................................... 1
17 Sleeve....................................................................................................................................... 1
18 Washer..................................................................................................................................... 3
19 Capscreww............................................................................................................................... 3
20 Lockwasher............................................................................................................................... 3
21 Plug........................................................................................................................................... 1
22 Plug........................................................................................................................................... 2
23 “O” Ring.................................................................................................................................... 2
24 Pin - Dowel............................................................................................................................... 2
25 Capscrew................................................................................................................................ 14
26 Capscrew.................................................................................................................................. 9
27 Lockwasher............................................................................................................................. 23
28 gasket - Converter to transmission case.................................................................................. 1
29 Bushing..................................................................................................................................... 1
30 Breather - Air............................................................................................................................. 1
31 Plug........................................................................................................................................... 1
32 Switch - Temperature................................................................................................................ 1
33 Adaptor - Temperature switch................................................................................................... 1
34 Sensor - Speed......................................................................................................................... 1
35 “O” Ring.................................................................................................................................... 1
36 Sensor - Speed 60mm.............................................................................................................. 1
37 Support - Speed sensor............................................................................................................ 2
38 Capscrew.................................................................................................................................. 2
39 Plug........................................................................................................................................... 2
40 Cover - Split flange................................................................................................................... 3
41 “O” ring...................................................................................................................................... 3
42 Capscrew................................................................................................................................ 12
43 Lockwasher............................................................................................................................. 12
44 Plug........................................................................................................................................... 1
45 “O” Ring.................................................................................................................................... 1

TE27/32 4 SD 03/2010 8-72

TRANSMISSION CASE & REAR COVER GROUPTE32
TRANSMISSION CASE GROUP

10
12

22 11
12

23 8

25
24 27

30
29
21 20 26
9

18 6
19 5
28
W

20 16 17 Y 6
21 5
34
X 6
5

5
35 6 W 14
32 33
29
31

5 W
6 X
1 Y
Y
4
5
6 15
W 3

2 X
Y

GRP-32021 rev. 092002

TE27/32 4 SD 03/2010 8-73

TRANSMISSION CASE & REAR COVER GROUP

Item Description Qty

1 Case - Transmission................................................................................................................. 1
2 Tube - 1st speed clutch pressure............................................................................................. 1
3 Tube - Low shaft rear bearing lube........................................................................................... 1
4 Tube - 3rd speed clutch pressure............................................................................................. 1
5 Sleeve - Pressure & lubr tube................................................................................................... 1
6 “O” ring...................................................................................................................................... 6
7 Cover - Rear............................................................................................................................. 1
8 Plug - Expansion...................................................................................................................... 1
9 Pin - Dowel............................................................................................................................... 2
10 Capscrew................................................................................................................................ 37
11 Capscrew.................................................................................................................................. 7
12 Lockwasher............................................................................................................................. 44
13 Gasket - Rear cover to transmission case................................................................................ 1
14 Plug........................................................................................................................................... 2
15 Plug - Magnetic drain................................................................................................................ 1
16 Sensor - Speed assy................................................................................................................ 1
17 “O” ring...................................................................................................................................... 1
18 Sensor - Speed assy................................................................................................................ 1
19 ‘O” ring...................................................................................................................................... 1
20 Support - Speed sensor............................................................................................................ 2
21 Capscrew.................................................................................................................................. 2
22 Tube - Suction.......................................................................................................................... 1
23 “O” ring...................................................................................................................................... 1
24 Lockwasher............................................................................................................................... 2
25 Capscrew.................................................................................................................................. 2
26 Baffle - Oil................................................................................................................................. 1
27 Cover - Oil baffle....................................................................................................................... 1
28 Tube - Oil baffle........................................................................................................................ 3
29 Lockwasher............................................................................................................................... 6
30 Capscrew.................................................................................................................................. 3
31 Screw........................................................................................................................................ 3
32 Cover - Split flange................................................................................................................... 1
33 “O” ring...................................................................................................................................... 1
34 Capscrew.................................................................................................................................. 4
35 Lockwasher............................................................................................................................... 4

TE27/32 4 SD 03/2010 8-74

TURBINE SHAFT GROUP
TE32
TURbINE SHAFT GROUP

2
15

16

14

9
6

8
7
11

12

10

13

1
3
4
5

GRP-TE32031 rev 230902

TE27/32 4 SD 03/2010 8-75

TURBINE SHAFT GROUP

Item Description Qty

1 Bearing - Turbine shaft front..................................................................................................... 1
2 Bearing - Turbine shaft rear...................................................................................................... 1
3 Spacer - Front bearing.............................................................................................................. 1
4 Snapring................................................................................................................................... 1
5 Ring - Piston............................................................................................................................. 1
6 Stator support assy................................................................................................................... 1
7 Screw - Stator support.............................................................................................................. 7
8 Lockwasher............................................................................................................................... 7
9 Ring - Piston............................................................................................................................. 1
10 Baffle - Oil................................................................................................................................. 1
11 Seal - Oil baffle......................................................................................................................... 1
12 Ring - Oil baffle seal................................................................................................................. 1
13 Ring - Oil baffle retaining.......................................................................................................... 1
14 “O” Ring.................................................................................................................................... 1
15 Snapring................................................................................................................................... 1
16 Turbine shaft............................................................................................................................. 1

TE27/32 4 SD 03/2010 8-76

 TE32
PUMP DRIVE GROUP

PUMP DRIVE GROUP

3
4
2

7
1

8
7
1 10

5
11
8
6
12

7
1 9

GRP-TE32051 rev 290802

TE27/32 4 SD 03/2010 8-77

PUMP DRIVE GROUP

Item Description Qty

1 Support - Pump drive bearing................................................................................................... 3
2 Screw - Bearing support........................................................................................................... 4
3 “O” Ring.................................................................................................................................... 4
4 Washer..................................................................................................................................... 4
5 Lockwasher............................................................................................................................... 2
6 Screw - Bearing support........................................................................................................... 2
7 Bearing - Pump drive gear........................................................................................................ 3
8 Snapring................................................................................................................................... 3
9 Gear - Aux. pump drive............................................................................................................. 2
10 Gear - Charging pump.............................................................................................................. 1
11 Gear - Impeller hub................................................................................................................... 1
12 Snapring................................................................................................................................... 1

TE27/32 4 SD 03/2010 8-78

Adaptor sleeve group

GRP-TE32201 rev.290502

TE27/32 4 SD 03/2010 8-79

Adaptor sleeve group

Item Description Qty

1 Sleeve - Pump drive................................................................................................................. 1
2 Snapring................................................................................................................................... 1

TE27/32 4 SD 03/2010 8-80